How to choose the right brushed and brushless motors

Which is more durable, a brushed motor or a brushless motor? How should one choose based on specific needs? This requires a comprehensive evaluation of their structural characteristics, applicable scenarios, and other factors.

In terms of durability, brushed motors and brushless motors each have their own characteristics, and their durability performance is closely related to the specific application scenarios and usage environments. Brushed motors have a relatively simple mechanical structure with an intuitive layout of core components, resulting in strong overall resistance to damage. However, they use a carbon brush commutation design, where the carbon brushes gradually wear down during high-speed operation, directly affecting the motor's lifespan. Therefore, regular replacement of the brushes is necessary to maintain performance, a requirement that becomes particularly evident in high-frequency usage scenarios.

In contrast, brushless motors have a more complex mechanical structure, using electronic commutation to replace traditional carbon brushes. They offer higher operational stability and do not require frequent brush maintenance, thereby reducing failures caused by wear. However, brushless motors have higher manufacturing costs and are generally more expensive than brushed motors. In scenarios where performance requirements are not stringent and cost control is a priority, their cost-effectiveness may not be as prominent as that of brushed motors.

When selecting a motor, consider the following key factors:

Application scenario: For high-performance, high-precision applications such as drones or precision machine tools, brushless motors offer superior smooth operation and control accuracy. In cost-sensitive scenarios with lower precision requirements, such as small household appliances or general-purpose power tools, brushed motors are more economical and practical.

Operating environment: Motor durability is influenced by environmental conditions. In harsh environments such as high temperatures, humidity, or dust, the carbon brushes of brushed motors are prone to corrosion and accelerated wear. In such cases, the sealed design and interference resistance of brushless motors better ensure longevity. However, in dry environments with moderate temperatures, the durability of brushed motors can also be effectively maintained.

Maintenance Requirements: Maintenance of brushed motors is relatively simple, with easy replacement of brushes that can be performed by ordinary users or maintenance personnel. While brushless motors do not require brush maintenance, once electronic component failures occur, repair procedures become more complex, requiring higher technical expertise, and maintenance costs may also increase.

Overall Cost: Brushless motors have higher initial procurement costs, but over the long term, their low maintenance frequency and longer lifespan may reduce overall costs. Brushed motors have lower initial investment costs, but the expenses associated with frequent brush replacements and the time costs of downtime for maintenance must be considered.

In summary, the choice between brushed and brushless motors hinges on matching specific application requirements and usage environments. When assessing durability, factors such as mechanical structure characteristics, environmental adaptability, maintenance convenience, and cost must be considered comprehensively to select the most suitable motor type.